US20130113313A1 - Rotary electric machine and method for manufacturing a stator coil connecting unit therefor - Google Patents
Rotary electric machine and method for manufacturing a stator coil connecting unit therefor Download PDFInfo
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- US20130113313A1 US20130113313A1 US13/450,098 US201213450098A US2013113313A1 US 20130113313 A1 US20130113313 A1 US 20130113313A1 US 201213450098 A US201213450098 A US 201213450098A US 2013113313 A1 US2013113313 A1 US 2013113313A1
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- United States
- Prior art keywords
- busbars
- coil
- terminals
- electrically insulating
- insulating holder
- Prior art date
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/09—Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
- Y10T29/49012—Rotor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49204—Contact or terminal manufacturing
- Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
- Y10T29/4922—Contact or terminal manufacturing by assembling plural parts with molding of insulation
Definitions
- the present invention relates to a rotary electric machine that is used in an automotive motor, for example, and to a method for manufacturing a stator coil connecting unit therefor.
- Conventional centralized distribution members for motors include: a plurality of approximately annular busbars that have: terminal portions that are connected to a battery; and tabs that are connected to windings of a stator, and that are disposed so as to correspond to respective phases of a motor; an electrically insulating holder that has holding grooves that hold the approximately annular busbars, which are disposed so as to be laminated radially on the centralized distribution member, so as to be separated from each other by a predetermined spacing; a resin electrically insulating layer that is formed by insert molding, and that covers the respective busbars and the insulating holder, the terminal portions extending radially outward from the respective approximately annular busbars, and the tabs extending radially inward from the respective approximately annular busbars (see Patent Literature 1, for example).
- Methods for manufacturing this conventional centralized distribution member for a motor have included a first bending step in which the terminal portions are bent outside the insulating holder; a second bending step in which the busbars are bent in thickness directions thereof so as to be made approximately annular; a step in which the approximately annular busbars are inserted into the plurality of holding grooves sequentially from those that are positioned on an outer circumferential side of the insulating holder; a third bending step in which the tabs are pointed inside the insulating holder after insertion of the respective busbars is completed; and a step in which insert molding is performed after completion of the respective bending steps.
- Patent Literature 1 Japanese Patent Laid-Open No. 2003-134759 (Gazette)
- the present invention aims to solve the above problems and an object of the present invention is to provide a rotary electric machine and a method for manufacturing a stator coil connecting unit therefor that can improve assembly and that can enable cost reductions by being constituted by: incomplete annular base portions from which a portion of a circular arc is omitted; external electric power supply terminals that extend outward on first sides in a radial direction from first sides in width directions of circumferential end portions of the base portions; and a plurality of coil connecting terminals that respectively extend outward on second sides in the radial direction from the first sides in the width directions of the base portions, and that are arranged circumferentially, in which busbars that are disposed so as to correspond to respective phases of the stator coil are mounted to an electrically insulating holder such that the external electric power supply terminals of the busbars that are positioned on the second side in the radial direction of the electrically insulating holder pass over the omitted portions of the base portions of the busbars that are positioned on the
- a rotary electric machine including: a housing including: a cylindrical frame; and a pair of brackets that are disposed on two axial ends of the cylindrical frame; a rotor that is disposed inside the housing such that a shaft is rotatably supported by the pair of brackets; a stator that includes: a stator core in which a plurality of teeth are each disposed so as to project radially inward from an inner circumferential wall surface of an annular core back, and are arranged in a row at a predetermined pitch circumferentially; and a stator coil that is constituted by a plurality of concentrated winding coils that are wound onto each of the teeth, the stator being held by the cylindrical frame so as to surround the rotor; and a connecting unit that is disposed at a first axial end of the stator, and that performs predetermined connection of the plurality of concentrated winding coils.
- the connecting unit includes: a plurality of busbars each including: a base portion that has a rectangular cross section that is formed by bending a flat strip in a thickness direction into an incomplete annular shape from which a portion of a circular arc is omitted; an external electric power supply terminal that has a rectangular cross section that is bent in the thickness direction from a first side in a width direction of a circumferential end portion of the base portion to extend outward on a first side in the radial direction; and a plurality of coil connecting terminals that have rectangular cross sections that are each bent in the thickness direction from the first side in the width direction of the base portion to extend outward on a second side in the radial direction, that are arranged in a row so as to have a predetermined spacing in a circumferential direction of the base portion, and that are connected to coil terminals of the concentrated winding coils, the plurality of busbars being disposed so as to correspond respective phases of the stator coil; and an annular electrically insulating holder in which
- the plurality of busbars are held by the electrically insulating holder such that the external electric power supply terminals extend outward on the first side in the radial direction so as to pass over the omitted portions of the base portions of the busbars that are positioned on the first side in the radial direction of the electrically insulating holder.
- the plurality of busbars are held by the electrically insulating holder such that the external electric power supply terminals pass over the omitted portions of the base portions of the busbars that are positioned on the first side in the radial direction of the electrically insulating holder and extend outward on the first side in the radial direction
- the plurality of busbars which are bent such that the external electric power supply terminals and the coil connecting terminals extend outward from the base portions in radially opposite directions, can be mounted onto the electrically insulating holder without interfering with each other.
- FIG. 1 is a cross section that shows a rotary electric machine according to Embodiment 1 of the present invention
- FIG. 2 is an end elevation that shows a mounted state of a connecting unit of a stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 3 is an end elevation that shows the stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 4 is a cross section that is taken along Line IV-IV in FIG. 2 so as to be viewed in the direction of the arrows;
- FIG. 5 is a cross section that is taken along Line V-V in FIG. 2 so as to be viewed in the direction of the arrows;
- FIG. 6 is a partial cross section that shows a mounted state of a cover of the stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 7 is a partial cross section that shows the mounted state of the cover of the stator of the rotary electric machine according to Embodiment 1 of the present invention.
- FIG. 8 is a perspective that shows a core unit of the stator of the rotary electric machine according to Embodiment 1 of the present invention.
- FIG. 9 is a connection diagram of stator coil of the rotary electric machine according to Embodiment 1 of the present invention.
- FIG. 10 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention before insert molding;
- FIGS. 11A through 11D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention.
- FIGS. 12A through 12D are process diagrams that explain a method for forming a busbar that is used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention
- FIGS. 13A through 13D are partial end elevations that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according to Embodiment 1 of the present invention.
- FIGS. 14A through 14D are partial cross sections that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according to Embodiment 1 of the present invention.
- FIGS. 15A and 15B are end elevations that show variations of neutral-point connection busbars that are used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 16 is an end elevation that shows a mounted state of a connecting unit of a stator of a rotary electric machine according to Embodiment 2 of the present invention.
- FIG. 17 is a cross section that is taken along Line XVII-XVII in FIG. 16 so as to be viewed in the direction of the arrows;
- FIG. 18 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according to Embodiment 2 of the present invention before insert molding;
- FIGS. 19A through 19D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 2 of the present invention.
- FIG. 1 is a cross section that shows a rotary electric machine according to Embodiment 1 of the present invention
- FIG. 2 is an end elevation that shows a mounted state of a connecting unit of a stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 3 is an end elevation that shows the stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 4 is a cross section that is taken along Line IV-IV in FIG. 2 so as to be viewed in the direction of the arrows
- FIG. 5 is a cross section that is taken along Line V-V in FIG. 2 so as to be viewed in the direction of the arrows
- FIGS. 6 and 7 are respective partial cross sections that show a mounted state of a cover of the stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 8 is a perspective that shows a core unit of the stator of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 9 is a connection diagram of stator coil of the rotary electric machine according to Embodiment 1 of the present invention
- FIG. 10 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention before insert molding
- FIGS. 11A through 11D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention
- FIGS. 12A through 12D are process diagrams that explain a method for forming a busbar that is used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention
- FIGS. 13A through 13D are partial end elevations that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according to Embodiment 1 of the present invention
- FIGS. 14A through 14 D are partial cross sections that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according to Embodiment 1 of the present invention
- FIGS. 15A and 15B are end elevations that show variations of neutral-point connection busbars that are used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 1 of the present invention.
- FIGS. 6 and 7 show a mounted state of the cover in the partial cross sections that are shown in FIGS. 4 and 5 , respectively.
- a rotary electric machine 100 includes: a housing 1 ; a rotor 6 that is rotatably disposed inside the housing 1 ; a stator 20 that is held inside the housing 1 so as to surround the rotor 6 ; and a connecting unit 30 that is disposed at the first axial end of the stator 20 .
- the housing 1 includes: first and second brackets 2 and 3 ; and a metal cylindrical frame 4 that is held between the first and second brackets 2 and 3 from two axial ends, and that is held on the first and second brackets 2 and 3 by a fastening force from a bolt 5 that fastens the first and second brackets 2 and 3 .
- the rotor 6 includes, for example: a rotor core 7 in which eight permanent magnets 8 that function as poles are fixed to an outer circumferential surface by adhesion, etc.; a shaft 9 that is inserted through and fixed to a central axial position of the rotor core 7 ; and cooling fans 10 that are fixed to two axial end surfaces of the rotor core 7 .
- the rotor 6 is rotatably disposed inside the housing 1 such that the shaft 9 is rotatably supported by first and second bearings 11 and 12 that are disposed on the first and second brackets 2 and 3 .
- the stator 20 includes: an annular stator core 21 ; and a stator coil 23 that is mounted onto the stator core 21 .
- the stator coil 23 is constituted by twelve concentrated winding coils 24
- the twelve concentrated winding coils 24 are connected by the connecting unit 30 , which is disposed on an axial end of the stator 20 , and as shown in FIG. 9 , are configured into a three-phase alternating-current winding that is formed by wye-connecting a U-phase winding, a V-phase winding, and a W-phase winding in each of which four concentrated winding coils 24 are connected in parallel.
- the stator core 21 is configured annularly such that twelve core blocks 22 are arranged circumferentially, the core blocks 22 having T-shaped cross sections that are constituted by: a core back portion 22 a that has a circular arc-shaped cross section; and a tooth 22 b that is disposed so as to project radially inward from a circumferentially-central portion of an inner circumferential surface of the core back portion 22 a.
- Coil bobbins 26 are resin-molded bodies of an electrically insulating resin such as a nylon, and are disposed on two axial ends of the core blocks 22 . As shown in FIG. 8 , the concentrated winding coils 24 are formed by winding a conductor wire that is coated with an insulator for a predetermined number of winds around the tooth 22 b of the core block 22 and the coil bobbins 26 .
- the stator 20 is formed by inserting the twelve core blocks 22 onto which the concentrated winding coils 24 are wound into the cylindrical frame 4 so as to be arranged circumferentially such that the circumferential side surfaces of the core back portions 22 a are abutted to each other, and fixing them by shrinkage fitting, etc.
- two coil terminals 24 a and 24 b extend outward at a first axial end from the respective concentrated winding coils 24 .
- the core back portions 22 a are arranged so as to line up circumferentially to constitute an annular core back of the stator core 21 .
- the connecting unit 30 includes: a plurality of busbars 31 N, 31 U, 31 V, and 31 W that perform predetermined connection of the concentrated winding coils 24 ; an electrically insulating holder 33 that houses and holds the plurality of busbars 31 N, 31 U, 31 V, and 31 W; and an exterior molded member 35 that is formed so as to embed the electrically insulating holder 33 in which the busbars 31 N, 31 U, 31 V, and 31 W are housed and held by insert molding.
- the busbar 31 N is a neutral-point connecting busbar, and as shown in FIG. 11A , includes: an annular base portion 31 a that is formed by bending a flat strip in a thickness direction; and twelve coil connecting terminals 32 a that are respectively bent in the thickness direction from a first side in a width direction of the base portion 31 a so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially.
- the busbar 31 U is a U-phase connecting busbar, and as shown in FIG. 11B , includes: an incomplete annular base portion 31 b that is smaller in diameter than the base portion 31 a of the busbar 31 N, that is formed by bending a flat strip in a thickness direction, and that has an omitted portion 32 c from which a portion of a circular arc is omitted; four coil connecting terminals 32 b that are respectively bent in the thickness direction from the first side in the width direction of the base portion 31 b so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially; and an external electric power supply terminal 32 U that is bent in the thickness direction from the first side in the width direction of a first circumferential end of the base portion 31 b to extend radially inward.
- the busbar 31 V is a V-phase connecting busbar, and as shown in FIG. 11C , includes: an incomplete annular base portion 31 b that is smaller in diameter than the base portion 31 b of the busbar 31 U, that is formed by bending a flat strip in a thickness direction, and that has an omitted portion 32 c from which a portion of a circular arc is omitted; four coil connecting terminals 32 b that are respectively bent in the thickness direction from the first side in the width direction of the base portion 31 b so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially; and an external electric power supply terminal 32 V that is bent in the thickness direction from the first side in the width direction of a first circumferential end of the base portion 31 b to extend radially inward.
- the busbar 31 W is a W-phase connecting busbar, and as shown in FIG. 11D , includes: an incomplete annular base portion 31 b that is smaller in diameter than the base portion 31 b of the busbar 31 V, that is formed by bending a flat strip in a thickness direction, and that has an omitted portion 32 c from which a portion of a circular arc is omitted; four coil connecting terminals 32 b that are respectively bent in the thickness direction from the first side in the width direction of the base portion 31 b so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially; and an external electric power supply terminal 32 W that is bent in the thickness direction from the first side in the width direction of a first circumferential end of the base portion 31 b to extend radially inward.
- the circumferential direction of the base portions 31 a and 31 b corresponds to a longitudinal direction of the flat strip
- the thickness direction and width direction of the base portions 31 a and 31 b correspond to directions that are parallel to the short sides and the long sides in a rectangular cross section that is perpendicular to the longitudinal direction of the flat strip.
- the coil terminals 24 a of the concentrated winding coils 24 are connected to the coil connecting terminals 32 a , and the coil terminals 24 b are connected to the coil connecting terminals 32 b.
- a flat strip base portion 31 b that has a predetermined length from which the coil connecting terminals 32 b and the external electric power supply terminal 32 U extend outward on the first side in the width direction is punched from a strip-shaped electrically conductive member that is made from a copper sheet, etc., that has a sheet thickness of approximately 1 mm.
- the base portion 31 b is bent in the thickness direction to form the incomplete annular shape from which the portion of the circular arc is omitted.
- the respective coil connecting terminals 32 b are bent perpendicular to the thickness direction so as to extend radially outward, and the external electric power supply terminal 32 U is bent perpendicular to the thickness direction so as to extend radially inward.
- the respective tip end portions of the coil connecting terminals 32 b and the external electric power supply terminal 32 U are bent perpendicular to the thickness direction to obtain the busbar 31 U.
- the base portion 31 b , the coil connecting terminals 32 b , and the external electric power supply terminal 32 U have rectangular cross sections (oblong cross sections).
- the step of manufacturing the busbar 31 U has been explained as being divided into a plurality of steps, but the step of bending the base portion 31 b , and the steps of bending the coil connecting terminals 32 and the external electric power supply terminal 32 U may also be performed simultaneously.
- busbars 31 N, 31 V, and 31 W are also formed similarly using a pressing machine, explanation thereof will be omitted here.
- the electrically insulating holder 33 is formed annularly using an electrically insulating resin such as a nylon, and four annular busbar housing grooves 34 are formed concentrically thereon.
- the four busbar housing grooves 34 are respectively formed on the electrically insulating holder 33 so as to be able to house the base portions 31 a and 31 b of the busbars 31 N, 31 U, 31 V, and 31 W.
- the busbar 31 N is mounted onto the electrically insulating holder 33 by inserting the base portion 31 a thereof into the busbar housing groove 34 that is positioned at the outermost circumference.
- the busbar 31 U is mounted onto the electrically insulating holder 33 by inserting the base portion 31 b thereof into the second busbar housing groove 34 from the outer circumferential side.
- the busbar 31 V is mounted onto the electrically insulating holder 33 by inserting the base portion 31 b thereof into the third busbar housing groove 34 from the outer circumferential side such that the external electric power supply terminal 32 U is inserted into the omitted portion 32 c of the base portion 31 b.
- busbar 31 W is mounted onto the electrically insulating holder 33 by inserting the base portion 31 b thereof into the fourth busbar housing groove 34 from the outer circumferential side such that the external electric power supply terminals 32 U and 32 V are inserted into the omitted portion 32 c of the base portion 31 b.
- the busbars 31 N, 31 U, 31 V, and 31 W are thereby assembled onto the electrically insulating holder 33 , as shown in FIG. 10 .
- twelve pairs of coil connecting terminals 32 a and 32 b that extend radially outward from the electrically insulating holder 33 are arranged at a uniform angular pitch.
- the external electric power supply terminal 32 U extends radially inward from the electrically insulating holder 33 so as to pass over the omitted portions 32 c of the base portions 31 b of the busbars 31 V and 31 W, and the external electric power supply terminal 32 V extends radially inward from the electrically insulating holder 33 so as to pass over the omitted portion 32 c of the base portion 31 b of the busbar 31 W.
- the electrically insulating holder 33 on which the busbars 31 N, 31 U, 31 V, and 31 W are assembled is inserted into a mold that has a parting direction in an axial direction of the electrically insulating holder 33 .
- Two flat surfaces that are constituted by the long sides of the rectangular cross sections of the coil connecting terminals 32 a and 32 b and the external electric power supply terminal 32 U, 32 V, and 32 W are held by mating surfaces of the mold, and the connecting unit 30 is formed by insert-molding using an electrically insulating resin such as a nylon.
- the electrically insulating holder 33 , the base portions 31 a and 31 b , the root regions of the coil connecting terminals 32 a and 32 b and the root regions of the external electric power supply terminal 32 U, 32 V, and 32 W are thereby embedded in the annular exterior molded member 35 , the coil connecting terminals 32 a and 32 b extend radially outward from outer circumferential wall surfaces of the exterior molded member 35 , and the external electric power supply terminals 32 U, 32 V, and 32 W extend radially inward from inner circumferential wall surfaces of the exterior molded member 35 .
- the two flat surfaces that are constituted by the long sides of the rectangular cross sections of the coil connecting terminals 32 a and 32 b and the external electric power supply terminals 32 U, 32 V, and 32 W that extend out from the exterior molded member 35 are flush with each other.
- the coil terminal guiding member 36 is a resin-molded body that is made of an electrically insulating resin such as a nylon, and as shown in FIGS. 5 and 13B , includes: twenty-four guiding portions 36 a that are arranged in a row circumferentially so as to face the coil terminals 24 a and 24 b , and that each have a splayed guiding aperture 36 b; and an annular linking portion 36 c that links and holds the guiding portions 36 a integrally.
- the guide portions 36 a are held by the linking portions 36 c such that apertures near tapered ends of the guiding apertures 36 b thereof are positioned in a vicinity of the radially outer ends of the projecting ends of the coil connecting terminals 32 a and 32 b that are arranged in a row in a circumferential direction of the connecting unit 30 .
- a cover 37 is formed using an electrically insulating resin such as a nylon into an annular shape that covers joining portions between the coil terminals 24 a and 24 b and the coil connecting terminals 32 a and 32 b.
- stator 20 is assembled.
- a partial end elevation of the stator 20 is shown in FIG. 13A
- a partial cross section is shown in FIG. 14A .
- a coil terminal guiding member 36 is moved close to the first axial end surface of the stator 20 from an axial direction such that the splayed ends of the guiding apertures 36 b face toward the stator 20 .
- the coil terminals 24 a and 24 b extend outward from the guiding portions 36 a so as to pass through the guiding apertures 36 b.
- the connecting unit 30 is moved toward the first axial end surface of the stator 20 from an axial direction such that the coil connecting terminals 32 a and 32 b are positioned circumferentially so as to face the coil terminals 24 a and 24 b that extend outward from the guiding portions 36 a .
- the connecting unit 30 is disposed axially outside the concentrated winding coils 24 and radially inside the coil terminal guiding member 36 so as to be in contact with the concentrated winding coils 24 .
- the connecting unit 30 is positioned radially inside the core back of the stator core 21 , i.e., the core back portions 22 a of the core blocks 22 .
- the coil terminals 24 a and 24 b and the coil connecting terminals 32 a and 32 b are joined by welding, etc., to join the connecting unit 30 to the first axial end of the stator 20 as shown in FIG. 2 .
- the twelve concentrated winding coils 24 are connected by the connecting unit 30 , and are configured into a three-phase alternating-current winding that is formed by wye-connecting a U-phase winding, a V-phase winding, and a W-phase winding in each of which four concentrated winding coils 24 are connected in parallel, as shown in FIG. 9 .
- the cover 37 is mounted to the connecting unit 30 from an axial direction.
- the connecting unit 30 and the junction portions between the coil connecting terminals 32 a and 32 b and the coil terminals 24 a and 24 b are covered by the cover 37 .
- alternating-current electric power is supplied from an external electric power supply to the stator coil 23 by means of the external electric power supply terminals 32 U, 32 V, and 32 W, to drive the rotor 6 to rotate.
- This rotary electric machine 100 operates as an inner-rotor three-phase motor in which the number of magnetic poles is eight, and the number of slots is twelve.
- the busbar 31 N includes: an annular base portion 31 a; and twelve coil connecting terminals 32 a that extend radially outward from the first side in the width direction of the base portion 31 a and that are arranged at a uniform angular pitch circumferentially.
- the busbars 31 U, 31 V and 31 W include: incomplete annular base portions 31 b that have omitted portions 32 c; four coil connecting terminals 32 b that extend radially outward from the first side in the width direction of the base portion 31 b and that are arranged at a uniform angular pitch circumferentially; and external electric power supply terminals 32 U, 32 V, and 32 W that extend radially inward from the first side in the width direction of a first circumferential end of the base portion 31 b.
- the busbar 31 N is mounted onto the electrically insulating holder 33 by inserting the base portion 31 a into the busbar housing groove 34 at the outermost circumference of the electrically insulating holder 33 , and then the busbar 31 U is mounted onto the electrically insulating holder 33 by inserting the base portion 31 b into the second busbar housing groove 34 from the outer circumferential side.
- the busbar 31 V is mounted onto the electrically insulating holder 33 by inserting the base portion 31 b into the third busbar housing groove 34 from the outer circumferential side such that the external electric power supply terminal 32 U of the busbar 31 U that is already mounted is inserted into the omitted portion 32 c of the base portion 31 b.
- busbar 31 W is mounted onto the electrically insulating holder 33 by inserting the base portion 31 b thereof into the fourth busbar housing groove 34 from the outer circumferential side such that the external electric power supply terminals 32 U and 32 V of the busbars 31 U and 31 V that are already mounted are inserted into the omitted portion 32 c of the base portion 31 b.
- the busbars 31 N, 31 U, 31 V, and 31 W in which the coil connecting terminals 32 a and 32 b are bent radially outward and the external electric power supply terminals 32 U, 32 V, and 32 W are bent radially inward, can be mounted onto the electrically insulating holder 33 without interfering with each other.
- the coil connecting terminals 32 a and 32 b and the external electric power supply terminals 32 U, 32 V, and 32 W are bent perpendicular to the thickness directions of the base portions 31 a and 31 b.
- the parting direction of the mold can be set to the axial direction of the annular electrically insulating holder 33 , and the two flat surfaces that are constituted by the long sides of the rectangular cross sections of the coil connecting terminals 32 a and 32 b and the external electric power supply terminals 32 U, 32 V, and 32 W can be pressed by the mating surfaces and insert-molded.
- the connecting unit 30 is disposed axially outside the concentrated winding coils 24 , which are arranged annularly in a circumferential direction.
- the junction portions between the coil terminals 24 a and 24 b and the coil connecting terminals 32 a and 32 b are positioned radially outside the concentrated winding coils 24 where there is ample space for connecting work, improving work efficiency during joining.
- it becomes possible to widen the radial width of the connecting unit 30 radially inward, and increase the sheet thickness of the busbars 31 N, 31 U, 31 V, and 31 W increases in the supplied electric current can be accommodated easily without inviting increases in the size of the rotary electric machine 100 .
- the coil connecting terminals 32 a and 32 b and the external electric power supply terminals 32 U, 32 V, and 32 W extend outward in radially opposite directions, jigs for connecting the coil connecting terminals 32 a and 32 b and jigs for connecting the external electric power supply terminals 32 U, 32 V, and 32 W do not interfere with each other, improving work efficiency during joining.
- the coil terminal guiding members 36 are mounted such that the coil terminals 24 a and 24 b are inserted through the splayed guiding apertures 36 b from the splayed ends, the coil terminals 24 a and 24 b are guided by the splayed guiding apertures 36 b to extend outward from the guiding portions 36 a.
- the tip ends of the coil terminals 24 a and 24 b are arranged in a row circumferentially so as to lie alongside the tip ends of the coil connecting terminals 32 a and 32 b , simplifying the operation of joining the coil terminals 24 a and 24 b and the coil connecting terminals 32 a and 32 b.
- the connecting unit 30 is mounted such that the cover 37 covers the junction portions between the coil terminals 24 a and 24 b and the coil connecting terminals 32 a and 32 b , electrical insulation is improved.
- the busbar 31 N is formed into an annular shape, but as shown in FIG. 15A , the busbar 31 N may also be an incomplete annular shape that has an omitted portion.
- the busbar 31 N may also be configured such that four circular arc-shaped base portions 31 c that have three coil connecting terminals 32 a are arranged in a circumferential direction.
- FIG. 16 is an end elevation that shows a mounted state of a connecting unit of a stator of a rotary electric machine according to Embodiment 2 of the present invention
- FIG. 17 is a cross section that is taken along Line XVII-XVII in FIG. 16 so as to be viewed in the direction of the arrows
- FIG. 18 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according to Embodiment 2 of the present invention before insert molding
- FIGS. 19A through 19D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according to Embodiment 2 of the present invention.
- a connecting unit 40 includes: a plurality of busbars 41 N, 41 U, 41 V, and 41 W that perform predetermined connection of concentrated winding coils 24 ; an electrically insulating holder 33 that houses and holds the plurality of busbars 41 N, 41 U, 41 V, and 41 W; and an exterior molded member 35 that is formed so as to embed the electrically insulating holder 33 in which the busbars 41 N, 41 U, 41 V, and 41 W are housed and held by insert molding.
- the busbar 41 U is a U-phase connecting busbar, and as shown in FIG. 19A , includes: an incomplete annular base portion 41 b that is formed by bending a flat strip in a thickness direction, and that has an omitted portion 42 c from which a portion of a circular arc is omitted; four coil connecting terminals 42 b that are respectively bent in the thickness direction from a first side in a width direction of the base portion 41 b so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially; and an external electric power supply terminal 42 U that is bent in the thickness direction from the first side in the width direction of a first circumferential end of the base portion 41 b to extend radially outward.
- the busbar 41 V is a V-phase connecting busbar, and as shown in FIG. 19B , includes: an incomplete annular base portion 41 b that is smaller in diameter than the base portion 41 b of the busbar 41 U, that is formed by bending a flat strip in a thickness direction, and that has an omitted portion 42 c from which a portion of a circular arc is omitted; four coil connecting terminals 42 b that are respectively bent in the thickness direction from the first side in the width direction of the base portion 41 b so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially; and an external electric power supply terminal 42 V that is bent in the thickness direction from the first side in the width direction of a first circumferential end of the base portion 41 b to extend radially outward.
- the busbar 41 W is a W-phase connecting busbar, and as shown in FIG. 19C , includes: an incomplete annular base portion 41 b that is smaller in diameter than the base portion 41 b of the busbar 41 V, that is formed by bending a flat strip in a thickness direction, and that has an omitted portion 32 c from which a portion of a circular arc is omitted; four coil connecting terminals 42 b that are respectively bent in the thickness direction from the first side in the width direction of the base portion 41 b so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially; and an external electric power supply terminal 42 W that is bent in the thickness direction from the first side in the width direction of a first circumferential end of the base portion 41 b to extend radially outward.
- the busbar 41 N is a neutral-point connecting busbar, and as shown in FIG. 19D , includes: an annular base portion 41 a that is smaller in diameter than the base portion 41 b of the busbar 41 W, and that is formed by bending a flat strip in a thickness direction; and twelve coil connecting terminals 42 a that are respectively bent in the thickness direction from the first side in the width direction of the base portion 41 a so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially.
- coil terminals 24 a of the concentrated winding coils 24 are connected to the coil connecting terminals 42 a
- coil terminals 24 b are connected to the coil connecting terminals 42 b.
- the busbars 41 U, 41 V, 41 W, and 41 N are formed using a pressing machine from a strip-shaped electrically conductive member that is made from a copper sheet, etc., that has a sheet thickness of approximately 1 mm in a similar manner to the busbars 31 U, 31 V, 31 W, and 31 N.
- the busbar 41 N is mounted onto the electrically insulating holder 33 by inserting the base portion 41 a thereof into the busbar housing groove 34 that is positioned at the innermost circumference.
- the busbar 41 W is mounted onto the electrically insulating holder 33 by inserting the base portion 41 b thereof into the second busbar housing groove 34 from the inner circumferential side.
- the busbar 41 V is mounted onto the electrically insulating holder 33 by inserting the base portion 41 b thereof into the third busbar housing groove 34 from the inner circumferential side such that the external electric power supply terminal 42 W is inserted into the omitted portion 42 c of the base portion 41 b.
- busbar 41 U is mounted onto the electrically insulating holder 33 by inserting the base portion 41 b thereof into the fourth busbar housing groove 34 from the inner circumferential side, i.e., at the innermost circumference, such that the external electric power supply terminals 42 U and 42 W are inserted into the omitted portion 42 c of the base portion 41 b.
- the busbars 41 N, 41 U, 41 V, and 41 W are thereby assembled into the electrically insulating holder 33 , as shown in FIG. 18 .
- twelve pairs of coil connecting terminals 42 a and 42 b that extend radially inward from the electrically insulating holder 33 are arranged at a uniform angular pitch.
- the external electric power supply terminal 42 W extends radially outward from the electrically insulating holder 33 so as to pass over the omitted portions 42 c of the base portions 41 b of the busbars 41 U and 41 V, and the external electric power supply terminal 42 V extends radially outward from the electrically insulating holder 33 so as to pass over the omitted portion 42 c of the base portion 41 b of the busbar 41 U.
- the electrically insulating holder 33 on which the busbars 41 N, 41 U, 41 V, and 41 W are assembled is inserted into a mold that has a parting direction in an axial direction of the electrically insulating holder 33 .
- Two flat surfaces that are constituted by the long sides of the rectangular cross sections of the coil connecting terminals 42 a and 42 b and the external electric power supply terminal 42 U, 42 V, and 42 W are held by mating surfaces of the mold, and the connecting unit 40 is formed by insert-molding using an electrically insulating resin such as a nylon.
- the electrically insulating holder 33 , the base portions 41 a and 41 b , the root regions of the coil connecting terminals 42 a and 42 b and the root regions of the external electric power supply terminal 42 U, 42 V, and 42 W are thereby embedded in the annular exterior molded member 35 , the coil connecting terminals 42 a and 42 b extend radially inward from inner circumferential wall surfaces of the exterior molded member 35 , and the external electric power supply terminals 42 U, 42 V, and 42 W extend radially outward from outer circumferential wall surfaces of the exterior molded member 35 .
- the two flat surfaces that are constituted by the long sides of the rectangular cross sections of the coil connecting terminals 42 a and 42 b and the external electric power supply terminals 42 U, 42 V, and 42 W that extend out from the exterior molded member 35 are flush with each other.
- the connecting unit 40 is moved toward the first axial end surface of the stator 20 from an axial direction such that the coil connecting terminals 42 a and 42 b are positioned circumferentially so as to face the coil terminals 24 a and 24 b.
- the connecting unit 40 is disposed axially outside the stator core 21 and radially outside the concentrated winding coils 24 so as to be in contact with the core back portions 22 a.
- the connecting unit 40 is positioned radially outside the teeth 22 b of the stator core 21 .
- the coil terminals 24 a and 24 b and the coil connecting terminals 42 a and 42 b are joined by welding, etc., to join the connecting unit 40 to the first axial end of the stator 20 .
- the twelve concentrated winding coils 24 are connected by the connecting unit 40 , and are configured into a three-phase alternating-current winding that is formed by wye-connecting a U-phase winding, a V-phase winding, and a W-phase winding in each of which four concentrated winding coils 24 are connected in parallel, in a similar manner to Embodiment 1.
- coil terminal guiding members 36 and the cover 37 have not been used, it goes without saying that the coil terminal guiding members 36 and the cover 37 may also be used.
- the busbar 41 N is mounted onto the electrically insulating holder 33 by inserting the base portion 41 a into the busbar housing groove 34 at the innermost circumference of the electrically insulating holder 33 , and then the busbar 41 W is mounted onto the electrically insulating holder 33 by inserting the base portion 41 b into the second busbar housing groove 34 from the inner circumferential side.
- the busbar 41 V is mounted onto the electrically insulating holder 33 by inserting the base portion 41 b into the third busbar housing groove 34 from the inner circumferential side such that the external electric power supply terminal 42 W of the busbar 41 W that is already mounted is inserted into the omitted portion 42 c of the base portion 41 b.
- busbar 41 U is mounted onto the electrically insulating holder 33 by inserting the base portion 41 b thereof into the fourth busbar housing groove 34 from the inner circumferential side such that the external electric power supply terminals 42 V and 42 W of the busbars 41 V and 41 W that are already mounted are inserted into the omitted portion 42 c of the base portion 41 b.
- the busbars 41 N, 41 U, 41 V, and 41 W in which the coil connecting terminals 42 a and 42 b are bent radially inward, and the external electric power supply terminals 42 U, 42 V, and 42 W are bent radially outward, can be mounted onto the electrically insulating holder 33 without interfering with each other.
- the coil connecting terminals 42 a and 42 b and the external electric power supply terminals 42 U, 42 V, and 42 W are bent perpendicular to the thickness directions of the base portions 41 a and 41 b.
- the parting direction of the mold can be set to the axial direction of the annular electrically insulating holder 33 , and the two flat surfaces that are constituted by the long sides of the rectangular cross sections of the coil connecting terminals 42 a and 42 b and the external electric power supply terminals 42 U, 42 V, and 42 W can be pressed by the mating surfaces and insert-molded.
- the connecting unit 40 is disposed radially outside the concentrated winding coils 24 , which are arranged annularly in a circumferential direction, the external electric power supply terminals 42 U, 42 V, and 42 W that are bent radially outward from the base portions 41 b can be connected directly to an external electric power supply (not shown) simply by being extended outside the cylindrical frame 4 .
- an external electric power supply not shown
- connecting wiring, etc., between the external electric power supply and the external electric power supply terminals 42 U, 42 V, and 42 W is also no longer required, enabling the number of parts to be reduced.
- a ratio between a magnetic pole count and a slot count in the rotary electric machine is 8:12, i.e., a pole-to-slot ratio is 2:3, but the pole-to-slot ratio is not limited to 2:3, and may also be 4:3, for example.
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- Manufacture Of Motors, Generators (AREA)
Abstract
Description
- 1. Field of the Invention
- The present invention relates to a rotary electric machine that is used in an automotive motor, for example, and to a method for manufacturing a stator coil connecting unit therefor.
- 2. Description of the Related Art
- Conventional centralized distribution members for motors include: a plurality of approximately annular busbars that have: terminal portions that are connected to a battery; and tabs that are connected to windings of a stator, and that are disposed so as to correspond to respective phases of a motor; an electrically insulating holder that has holding grooves that hold the approximately annular busbars, which are disposed so as to be laminated radially on the centralized distribution member, so as to be separated from each other by a predetermined spacing; a resin electrically insulating layer that is formed by insert molding, and that covers the respective busbars and the insulating holder, the terminal portions extending radially outward from the respective approximately annular busbars, and the tabs extending radially inward from the respective approximately annular busbars (see
Patent Literature 1, for example). - Methods for manufacturing this conventional centralized distribution member for a motor have included a first bending step in which the terminal portions are bent outside the insulating holder; a second bending step in which the busbars are bent in thickness directions thereof so as to be made approximately annular; a step in which the approximately annular busbars are inserted into the plurality of holding grooves sequentially from those that are positioned on an outer circumferential side of the insulating holder; a third bending step in which the tabs are pointed inside the insulating holder after insertion of the respective busbars is completed; and a step in which insert molding is performed after completion of the respective bending steps.
- Patent Literature 1: Japanese Patent Laid-Open No. 2003-134759 (Gazette)
- Because conventional centralized distribution members for motors have configurations in which the terminal portions and the tabs extend outward from each of the approximately annular busbars in radially opposite directions, if the terminal portions and the tabs are both bent in steps before the approximately annular busbars are inserted into the holding grooves of the insulating holder, as the busbars are inserted into the holding grooves of the insulating holder, they interfere with the busbars that are already inserted into the holding grooves, and cannot be inserted into the holding grooves.
- Thus, in conventional methods for manufacturing centralized distribution members for motors, only the terminal portions are bent in a step before the approximately annular busbars are inserted into the holding grooves of the insulating holder, and the tabs are bent in a reverse direction to the terminal portions after completion of insertion of the plurality of busbars into the plurality of holding grooves. However, one problem has been that bending of the tabs in a state in which the plurality of busbars are inserted into the respective holding grooves of the insulating holder is complicated bending, reducing ease of assembly of the centralized distribution member, and giving rise to cost increases.
- The present invention aims to solve the above problems and an object of the present invention is to provide a rotary electric machine and a method for manufacturing a stator coil connecting unit therefor that can improve assembly and that can enable cost reductions by being constituted by: incomplete annular base portions from which a portion of a circular arc is omitted; external electric power supply terminals that extend outward on first sides in a radial direction from first sides in width directions of circumferential end portions of the base portions; and a plurality of coil connecting terminals that respectively extend outward on second sides in the radial direction from the first sides in the width directions of the base portions, and that are arranged circumferentially, in which busbars that are disposed so as to correspond to respective phases of the stator coil are mounted to an electrically insulating holder such that the external electric power supply terminals of the busbars that are positioned on the second side in the radial direction of the electrically insulating holder pass over the omitted portions of the base portions of the busbars that are positioned on the first side in the radial direction of the electrically insulating holder and extend outward on the first side in the radial direction to eliminate need for a step of bending the external electric power supply terminals or the coil connecting terminals after completion of mounting of the busbars onto the electrically insulating holder.
- In order to achieve the above object, according to one aspect of the present invention, there is provided a rotary electric machine including: a housing including: a cylindrical frame; and a pair of brackets that are disposed on two axial ends of the cylindrical frame; a rotor that is disposed inside the housing such that a shaft is rotatably supported by the pair of brackets; a stator that includes: a stator core in which a plurality of teeth are each disposed so as to project radially inward from an inner circumferential wall surface of an annular core back, and are arranged in a row at a predetermined pitch circumferentially; and a stator coil that is constituted by a plurality of concentrated winding coils that are wound onto each of the teeth, the stator being held by the cylindrical frame so as to surround the rotor; and a connecting unit that is disposed at a first axial end of the stator, and that performs predetermined connection of the plurality of concentrated winding coils. The connecting unit includes: a plurality of busbars each including: a base portion that has a rectangular cross section that is formed by bending a flat strip in a thickness direction into an incomplete annular shape from which a portion of a circular arc is omitted; an external electric power supply terminal that has a rectangular cross section that is bent in the thickness direction from a first side in a width direction of a circumferential end portion of the base portion to extend outward on a first side in the radial direction; and a plurality of coil connecting terminals that have rectangular cross sections that are each bent in the thickness direction from the first side in the width direction of the base portion to extend outward on a second side in the radial direction, that are arranged in a row so as to have a predetermined spacing in a circumferential direction of the base portion, and that are connected to coil terminals of the concentrated winding coils, the plurality of busbars being disposed so as to correspond respective phases of the stator coil; and an annular electrically insulating holder in which a plurality of busbar housing grooves are formed concentrically, and that holds the plurality of busbars by housing the base portions in each of the plurality of busbar housing grooves. The plurality of busbars are held by the electrically insulating holder such that the external electric power supply terminals extend outward on the first side in the radial direction so as to pass over the omitted portions of the base portions of the busbars that are positioned on the first side in the radial direction of the electrically insulating holder.
- According to the present invention, because the plurality of busbars are held by the electrically insulating holder such that the external electric power supply terminals pass over the omitted portions of the base portions of the busbars that are positioned on the first side in the radial direction of the electrically insulating holder and extend outward on the first side in the radial direction, the plurality of busbars, which are bent such that the external electric power supply terminals and the coil connecting terminals extend outward from the base portions in radially opposite directions, can be mounted onto the electrically insulating holder without interfering with each other. Thus, complicated bending steps in which the external electric power supply terminals and the coil connecting terminals are bent after mounting the busbars onto the electrically insulating holder are no longer required, enabling assembly of the connecting unit of the stator coil to be improved, and also enabling cost reductions.
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FIG. 1 is a cross section that shows a rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 2 is an end elevation that shows a mounted state of a connecting unit of a stator of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 3 is an end elevation that shows the stator of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 4 is a cross section that is taken along Line IV-IV inFIG. 2 so as to be viewed in the direction of the arrows; -
FIG. 5 is a cross section that is taken along Line V-V inFIG. 2 so as to be viewed in the direction of the arrows; -
FIG. 6 is a partial cross section that shows a mounted state of a cover of the stator of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 7 is a partial cross section that shows the mounted state of the cover of the stator of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 8 is a perspective that shows a core unit of the stator of the rotary electric machine according to Embodiment 1 of the present invention; -
FIG. 9 is a connection diagram of stator coil of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 10 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention before insert molding; -
FIGS. 11A through 11D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIGS. 12A through 12D are process diagrams that explain a method for forming a busbar that is used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIGS. 13A through 13D are partial end elevations that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according toEmbodiment 1 of the present invention; -
FIGS. 14A through 14D are partial cross sections that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according toEmbodiment 1 of the present invention; -
FIGS. 15A and 15B are end elevations that show variations of neutral-point connection busbars that are used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention; -
FIG. 16 is an end elevation that shows a mounted state of a connecting unit of a stator of a rotary electric machine according toEmbodiment 2 of the present invention; -
FIG. 17 is a cross section that is taken along Line XVII-XVII inFIG. 16 so as to be viewed in the direction of the arrows; -
FIG. 18 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 2 of the present invention before insert molding; and -
FIGS. 19A through 19D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 2 of the present invention. - Preferred embodiments of a rotary electric machine and a method for manufacturing a stator coil connecting unit therefor according to the present invention will now be explained using the drawings.
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FIG. 1 is a cross section that shows a rotary electric machine according toEmbodiment 1 of the present invention,FIG. 2 is an end elevation that shows a mounted state of a connecting unit of a stator of the rotary electric machine according toEmbodiment 1 of the present invention,FIG. 3 is an end elevation that shows the stator of the rotary electric machine according toEmbodiment 1 of the present invention,FIG. 4 is a cross section that is taken along Line IV-IV inFIG. 2 so as to be viewed in the direction of the arrows,FIG. 5 is a cross section that is taken along Line V-V inFIG. 2 so as to be viewed in the direction of the arrows,FIGS. 6 and 7 are respective partial cross sections that show a mounted state of a cover of the stator of the rotary electric machine according toEmbodiment 1 of the present invention,FIG. 8 is a perspective that shows a core unit of the stator of the rotary electric machine according toEmbodiment 1 of the present invention,FIG. 9 is a connection diagram of stator coil of the rotary electric machine according toEmbodiment 1 of the present invention,FIG. 10 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention before insert molding,FIGS. 11A through 11D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention,FIGS. 12A through 12D are process diagrams that explain a method for forming a busbar that is used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention,FIGS. 13A through 13D are partial end elevations that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according toEmbodiment 1 of the present invention,FIGS. 14A through 14D are partial cross sections that explain a method for assembling a connecting unit onto the stator in the rotary electric machine according toEmbodiment 1 of the present invention, andFIGS. 15A and 15B are end elevations that show variations of neutral-point connection busbars that are used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 1 of the present invention. Moreover,FIGS. 6 and 7 show a mounted state of the cover in the partial cross sections that are shown inFIGS. 4 and 5 , respectively. - In
FIG. 1 , a rotaryelectric machine 100 includes: ahousing 1; arotor 6 that is rotatably disposed inside thehousing 1; astator 20 that is held inside thehousing 1 so as to surround therotor 6; and a connectingunit 30 that is disposed at the first axial end of thestator 20. - The
housing 1 includes: first andsecond brackets cylindrical frame 4 that is held between the first andsecond brackets second brackets bolt 5 that fastens the first andsecond brackets - The
rotor 6 includes, for example: a rotor core 7 in which eight permanent magnets 8 that function as poles are fixed to an outer circumferential surface by adhesion, etc.; a shaft 9 that is inserted through and fixed to a central axial position of the rotor core 7; andcooling fans 10 that are fixed to two axial end surfaces of the rotor core 7. Therotor 6 is rotatably disposed inside thehousing 1 such that the shaft 9 is rotatably supported by first andsecond bearings 11 and 12 that are disposed on the first andsecond brackets - The
stator 20 includes: anannular stator core 21; and astator coil 23 that is mounted onto thestator core 21. As described below, thestator coil 23 is constituted by twelve concentratedwinding coils 24, the twelve concentratedwinding coils 24 are connected by the connectingunit 30, which is disposed on an axial end of thestator 20, and as shown inFIG. 9 , are configured into a three-phase alternating-current winding that is formed by wye-connecting a U-phase winding, a V-phase winding, and a W-phase winding in each of which four concentratedwinding coils 24 are connected in parallel. - Next, configuration of the
stator 20 will be explained in detail. - As shown in
FIGS. 3 and 8 , thestator core 21 is configured annularly such that twelvecore blocks 22 are arranged circumferentially, thecore blocks 22 having T-shaped cross sections that are constituted by: acore back portion 22 a that has a circular arc-shaped cross section; and atooth 22 b that is disposed so as to project radially inward from a circumferentially-central portion of an inner circumferential surface of thecore back portion 22 a. -
Coil bobbins 26 are resin-molded bodies of an electrically insulating resin such as a nylon, and are disposed on two axial ends of thecore blocks 22. As shown inFIG. 8 , the concentratedwinding coils 24 are formed by winding a conductor wire that is coated with an insulator for a predetermined number of winds around thetooth 22 b of thecore block 22 and thecoil bobbins 26. - The
stator 20 is formed by inserting the twelve core blocks 22 onto which the concentrated windingcoils 24 are wound into thecylindrical frame 4 so as to be arranged circumferentially such that the circumferential side surfaces of the core backportions 22 a are abutted to each other, and fixing them by shrinkage fitting, etc. In astator 20 that is configured in this manner, twocoil terminals coils 24. The core backportions 22 a are arranged so as to line up circumferentially to constitute an annular core back of thestator core 21. - Next, configuration of the connecting
unit 30 will be explained usingFIGS. 4 , 5, 10, and 11A through 11D. - As shown in
FIGS. 4 , 5, and 10, the connectingunit 30 includes: a plurality ofbusbars coils 24; an electrically insulatingholder 33 that houses and holds the plurality ofbusbars member 35 that is formed so as to embed the electrically insulatingholder 33 in which thebusbars - The
busbar 31N is a neutral-point connecting busbar, and as shown inFIG. 11A , includes: anannular base portion 31 a that is formed by bending a flat strip in a thickness direction; and twelvecoil connecting terminals 32 a that are respectively bent in the thickness direction from a first side in a width direction of thebase portion 31 a so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially. - The
busbar 31U is a U-phase connecting busbar, and as shown inFIG. 11B , includes: an incompleteannular base portion 31 b that is smaller in diameter than thebase portion 31 a of thebusbar 31N, that is formed by bending a flat strip in a thickness direction, and that has an omittedportion 32 c from which a portion of a circular arc is omitted; fourcoil connecting terminals 32 b that are respectively bent in the thickness direction from the first side in the width direction of thebase portion 31 b so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially; and an external electricpower supply terminal 32U that is bent in the thickness direction from the first side in the width direction of a first circumferential end of thebase portion 31 b to extend radially inward. - The
busbar 31V is a V-phase connecting busbar, and as shown inFIG. 11C , includes: an incompleteannular base portion 31 b that is smaller in diameter than thebase portion 31 b of thebusbar 31U, that is formed by bending a flat strip in a thickness direction, and that has an omittedportion 32 c from which a portion of a circular arc is omitted; fourcoil connecting terminals 32 b that are respectively bent in the thickness direction from the first side in the width direction of thebase portion 31 b so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially; and an external electricpower supply terminal 32V that is bent in the thickness direction from the first side in the width direction of a first circumferential end of thebase portion 31 b to extend radially inward. - The
busbar 31W is a W-phase connecting busbar, and as shown inFIG. 11D , includes: an incompleteannular base portion 31 b that is smaller in diameter than thebase portion 31 b of thebusbar 31V, that is formed by bending a flat strip in a thickness direction, and that has an omittedportion 32 c from which a portion of a circular arc is omitted; fourcoil connecting terminals 32 b that are respectively bent in the thickness direction from the first side in the width direction of thebase portion 31 b so as to extend radially outward and that are arranged at a uniform angular pitch circumferentially; and an external electricpower supply terminal 32W that is bent in the thickness direction from the first side in the width direction of a first circumferential end of thebase portion 31 b to extend radially inward. - Moreover, the circumferential direction of the
base portions base portions - The
coil terminals 24 a of the concentrated windingcoils 24 are connected to thecoil connecting terminals 32 a, and thecoil terminals 24 b are connected to thecoil connecting terminals 32 b. - A method for manufacturing the
busbar 31U using a pressing machine (not shown) will now be explained with reference toFIG. 12 . - First, as shown in
FIG. 12A , a flatstrip base portion 31 b that has a predetermined length from which thecoil connecting terminals 32 b and the external electricpower supply terminal 32U extend outward on the first side in the width direction is punched from a strip-shaped electrically conductive member that is made from a copper sheet, etc., that has a sheet thickness of approximately 1 mm. Next, as shown inFIG. 12B , thebase portion 31 b is bent in the thickness direction to form the incomplete annular shape from which the portion of the circular arc is omitted. Next, as shown inFIG. 12C , the respectivecoil connecting terminals 32 b are bent perpendicular to the thickness direction so as to extend radially outward, and the external electricpower supply terminal 32U is bent perpendicular to the thickness direction so as to extend radially inward. In addition, as shown inFIG. 12D , the respective tip end portions of thecoil connecting terminals 32 b and the external electricpower supply terminal 32U are bent perpendicular to the thickness direction to obtain thebusbar 31U. Moreover, thebase portion 31 b, thecoil connecting terminals 32 b, and the external electricpower supply terminal 32U have rectangular cross sections (oblong cross sections). - Moreover, to facilitate explanation, the step of manufacturing the
busbar 31U has been explained as being divided into a plurality of steps, but the step of bending thebase portion 31 b, and the steps of bending thecoil connecting terminals 32 and the external electricpower supply terminal 32U may also be performed simultaneously. - Because the
busbars - As shown in
FIGS. 4 , 5, and 10, the electrically insulatingholder 33 is formed annularly using an electrically insulating resin such as a nylon, and four annularbusbar housing grooves 34 are formed concentrically thereon. The fourbusbar housing grooves 34 are respectively formed on the electrically insulatingholder 33 so as to be able to house thebase portions busbars - The
busbar 31N is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 a thereof into thebusbar housing groove 34 that is positioned at the outermost circumference. Next, thebusbar 31U is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 b thereof into the secondbusbar housing groove 34 from the outer circumferential side. Next, thebusbar 31V is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 b thereof into the thirdbusbar housing groove 34 from the outer circumferential side such that the external electricpower supply terminal 32U is inserted into the omittedportion 32 c of thebase portion 31 b. In addition, thebusbar 31W is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 b thereof into the fourthbusbar housing groove 34 from the outer circumferential side such that the external electricpower supply terminals portion 32 c of thebase portion 31 b. - The
busbars holder 33, as shown inFIG. 10 . Thus, twelve pairs ofcoil connecting terminals holder 33 are arranged at a uniform angular pitch. The external electricpower supply terminal 32U extends radially inward from the electrically insulatingholder 33 so as to pass over the omittedportions 32 c of thebase portions 31 b of thebusbars power supply terminal 32V extends radially inward from the electrically insulatingholder 33 so as to pass over the omittedportion 32 c of thebase portion 31 b of thebusbar 31W. - Next, the electrically insulating
holder 33 on which thebusbars holder 33. Two flat surfaces that are constituted by the long sides of the rectangular cross sections of thecoil connecting terminals power supply terminal unit 30 is formed by insert-molding using an electrically insulating resin such as a nylon. The electrically insulatingholder 33, thebase portions coil connecting terminals power supply terminal member 35, thecoil connecting terminals member 35, and the external electricpower supply terminals member 35. In addition, the two flat surfaces that are constituted by the long sides of the rectangular cross sections of thecoil connecting terminals power supply terminals member 35 are flush with each other. - The coil
terminal guiding member 36 is a resin-molded body that is made of an electrically insulating resin such as a nylon, and as shown inFIGS. 5 and 13B , includes: twenty-fourguiding portions 36 a that are arranged in a row circumferentially so as to face thecoil terminals aperture 36 b; and anannular linking portion 36 c that links and holds the guidingportions 36 a integrally. Theguide portions 36 a are held by the linkingportions 36 c such that apertures near tapered ends of the guidingapertures 36 b thereof are positioned in a vicinity of the radially outer ends of the projecting ends of thecoil connecting terminals unit 30. - A
cover 37 is formed using an electrically insulating resin such as a nylon into an annular shape that covers joining portions between thecoil terminals coil connecting terminals - A procedure for connecting the concentrated winding
coils 24 of thestator 20 using a connectingunit 30 that is configured in this manner will be explained with reference toFIGS. 13 and 14 . - First, the
stator 20 is assembled. A partial end elevation of thestator 20 is shown inFIG. 13A , and a partial cross section is shown inFIG. 14A . - Next, a coil
terminal guiding member 36 is moved close to the first axial end surface of thestator 20 from an axial direction such that the splayed ends of the guidingapertures 36 b face toward thestator 20. Thus, as shown inFIGS. 13B and 14B , thecoil terminals portions 36 a so as to pass through the guidingapertures 36 b. - Next, the connecting
unit 30 is moved toward the first axial end surface of thestator 20 from an axial direction such that thecoil connecting terminals coil terminals portions 36 a. Thus, as shown inFIGS. 13C and 14C , the connectingunit 30 is disposed axially outside the concentrated windingcoils 24 and radially inside the coilterminal guiding member 36 so as to be in contact with the concentrated windingcoils 24. Here, the connectingunit 30 is positioned radially inside the core back of thestator core 21, i.e., the core backportions 22 a of the core blocks 22. - Next, the
coil terminals coil connecting terminals unit 30 to the first axial end of thestator 20 as shown inFIG. 2 . Thus, the twelve concentrated windingcoils 24 are connected by the connectingunit 30, and are configured into a three-phase alternating-current winding that is formed by wye-connecting a U-phase winding, a V-phase winding, and a W-phase winding in each of which four concentrated windingcoils 24 are connected in parallel, as shown inFIG. 9 . - In addition, as shown in
FIGS. 13D and 14D , thecover 37 is mounted to the connectingunit 30 from an axial direction. Thus, as shown inFIGS. 6 and 7 , the connectingunit 30 and the junction portions between thecoil connecting terminals coil terminals cover 37. - In a rotary
electric machine 100 that is configured in this manner, alternating-current electric power is supplied from an external electric power supply to thestator coil 23 by means of the external electricpower supply terminals rotor 6 to rotate. This rotaryelectric machine 100 operates as an inner-rotor three-phase motor in which the number of magnetic poles is eight, and the number of slots is twelve. - According to
Embodiment 1, thebusbar 31N includes: anannular base portion 31 a; and twelvecoil connecting terminals 32 a that extend radially outward from the first side in the width direction of thebase portion 31 a and that are arranged at a uniform angular pitch circumferentially. Thebusbars annular base portions 31 b that have omittedportions 32 c; fourcoil connecting terminals 32 b that extend radially outward from the first side in the width direction of thebase portion 31 b and that are arranged at a uniform angular pitch circumferentially; and external electricpower supply terminals base portion 31 b. - The
busbar 31N is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 a into thebusbar housing groove 34 at the outermost circumference of the electrically insulatingholder 33, and then thebusbar 31U is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 b into the secondbusbar housing groove 34 from the outer circumferential side. Next, thebusbar 31V is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 b into the thirdbusbar housing groove 34 from the outer circumferential side such that the external electricpower supply terminal 32U of thebusbar 31U that is already mounted is inserted into the omittedportion 32 c of thebase portion 31 b. In addition, thebusbar 31W is mounted onto the electrically insulatingholder 33 by inserting thebase portion 31 b thereof into the fourthbusbar housing groove 34 from the outer circumferential side such that the external electricpower supply terminals busbars portion 32 c of thebase portion 31 b. - According to this assembly procedure, the
busbars coil connecting terminals power supply terminals holder 33 without interfering with each other. Thus, complicated bending steps in which thecoil connecting terminals power supply terminals busbars holder 33, and jigs that are used in the bending steps, etc., are no longer necessary, improving assembly of the connectingunit 30, and enabling costs to be reduced. - Because the
coil connecting terminals power supply terminals busbars holder 33, dimensional precision of the bent portions is increased. - The
coil connecting terminals power supply terminals base portions holder 33, and the two flat surfaces that are constituted by the long sides of the rectangular cross sections of thecoil connecting terminals power supply terminals coil connecting terminals power supply terminals - The connecting
unit 30 is disposed axially outside the concentrated windingcoils 24, which are arranged annularly in a circumferential direction. Thus, the junction portions between thecoil terminals coil connecting terminals coils 24 where there is ample space for connecting work, improving work efficiency during joining. In addition, because it becomes possible to widen the radial width of the connectingunit 30 radially inward, and increase the sheet thickness of thebusbars electric machine 100. - Because the
coil connecting terminals power supply terminals coil connecting terminals power supply terminals - Because the coil
terminal guiding members 36 are mounted such that thecoil terminals apertures 36 b from the splayed ends, thecoil terminals apertures 36 b to extend outward from the guidingportions 36 a. Thus, the tip ends of thecoil terminals coil connecting terminals coil terminals coil connecting terminals - Because the connecting
unit 30 is mounted such that thecover 37 covers the junction portions between thecoil terminals coil connecting terminals - Moreover, in
Embodiment 1 above, thebusbar 31N is formed into an annular shape, but as shown inFIG. 15A , thebusbar 31N may also be an incomplete annular shape that has an omitted portion. In addition, as shown inFIG. 15B , thebusbar 31N may also be configured such that four circular arc-shaped base portions 31 c that have threecoil connecting terminals 32 a are arranged in a circumferential direction. -
FIG. 16 is an end elevation that shows a mounted state of a connecting unit of a stator of a rotary electric machine according toEmbodiment 2 of the present invention,FIG. 17 is a cross section that is taken along Line XVII-XVII inFIG. 16 so as to be viewed in the direction of the arrows,FIG. 18 is an end elevation that shows a state of the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 2 of the present invention before insert molding, andFIGS. 19A through 19D are end elevations that show busbars that are used in the connecting unit of the stator coil of the rotary electric machine according toEmbodiment 2 of the present invention. - In
FIGS. 16 through 18 , a connectingunit 40 includes: a plurality ofbusbars coils 24; an electrically insulatingholder 33 that houses and holds the plurality ofbusbars member 35 that is formed so as to embed the electrically insulatingholder 33 in which thebusbars - The
busbar 41U is a U-phase connecting busbar, and as shown inFIG. 19A , includes: an incompleteannular base portion 41 b that is formed by bending a flat strip in a thickness direction, and that has an omittedportion 42 c from which a portion of a circular arc is omitted; fourcoil connecting terminals 42 b that are respectively bent in the thickness direction from a first side in a width direction of thebase portion 41 b so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially; and an external electricpower supply terminal 42U that is bent in the thickness direction from the first side in the width direction of a first circumferential end of thebase portion 41 b to extend radially outward. - The
busbar 41V is a V-phase connecting busbar, and as shown inFIG. 19B , includes: an incompleteannular base portion 41 b that is smaller in diameter than thebase portion 41 b of thebusbar 41U, that is formed by bending a flat strip in a thickness direction, and that has an omittedportion 42 c from which a portion of a circular arc is omitted; fourcoil connecting terminals 42 b that are respectively bent in the thickness direction from the first side in the width direction of thebase portion 41 b so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially; and an external electricpower supply terminal 42V that is bent in the thickness direction from the first side in the width direction of a first circumferential end of thebase portion 41 b to extend radially outward. - The
busbar 41W is a W-phase connecting busbar, and as shown inFIG. 19C , includes: an incompleteannular base portion 41 b that is smaller in diameter than thebase portion 41 b of thebusbar 41V, that is formed by bending a flat strip in a thickness direction, and that has an omittedportion 32 c from which a portion of a circular arc is omitted; fourcoil connecting terminals 42 b that are respectively bent in the thickness direction from the first side in the width direction of thebase portion 41 b so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially; and an external electricpower supply terminal 42W that is bent in the thickness direction from the first side in the width direction of a first circumferential end of thebase portion 41 b to extend radially outward. - The
busbar 41N is a neutral-point connecting busbar, and as shown inFIG. 19D , includes: anannular base portion 41 a that is smaller in diameter than thebase portion 41 b of thebusbar 41W, and that is formed by bending a flat strip in a thickness direction; and twelvecoil connecting terminals 42 a that are respectively bent in the thickness direction from the first side in the width direction of thebase portion 41 a so as to extend radially inward and that are arranged at a uniform angular pitch circumferentially. - Moreover,
coil terminals 24 a of the concentrated windingcoils 24 are connected to thecoil connecting terminals 42 a, andcoil terminals 24 b are connected to thecoil connecting terminals 42 b. - Next, a method for manufacturing the connecting
unit 40 will be explained. - First, the
busbars busbars - The
busbar 41N is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 a thereof into thebusbar housing groove 34 that is positioned at the innermost circumference. Next, thebusbar 41W is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 b thereof into the secondbusbar housing groove 34 from the inner circumferential side. Next, thebusbar 41V is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 b thereof into the thirdbusbar housing groove 34 from the inner circumferential side such that the external electricpower supply terminal 42W is inserted into the omittedportion 42 c of thebase portion 41 b. In addition, thebusbar 41U is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 b thereof into the fourthbusbar housing groove 34 from the inner circumferential side, i.e., at the innermost circumference, such that the external electricpower supply terminals portion 42 c of thebase portion 41 b. - The
busbars holder 33, as shown inFIG. 18 . Thus, twelve pairs ofcoil connecting terminals holder 33 are arranged at a uniform angular pitch. The external electricpower supply terminal 42W extends radially outward from the electrically insulatingholder 33 so as to pass over the omittedportions 42 c of thebase portions 41 b of thebusbars power supply terminal 42V extends radially outward from the electrically insulatingholder 33 so as to pass over the omittedportion 42 c of thebase portion 41 b of thebusbar 41U. - Next, the electrically insulating
holder 33 on which thebusbars holder 33. Two flat surfaces that are constituted by the long sides of the rectangular cross sections of thecoil connecting terminals power supply terminal unit 40 is formed by insert-molding using an electrically insulating resin such as a nylon. The electrically insulatingholder 33, thebase portions coil connecting terminals power supply terminal member 35, thecoil connecting terminals member 35, and the external electricpower supply terminals member 35. In addition, the two flat surfaces that are constituted by the long sides of the rectangular cross sections of thecoil connecting terminals power supply terminals member 35 are flush with each other. - A procedure for connecting the concentrated winding
coils 24 of thestator 20 using a connectingunit 40 that is configured in this manner will be explained. - First, the connecting
unit 40 is moved toward the first axial end surface of thestator 20 from an axial direction such that thecoil connecting terminals coil terminals FIGS. 16 and 17 , the connectingunit 40 is disposed axially outside thestator core 21 and radially outside the concentrated windingcoils 24 so as to be in contact with the core backportions 22 a. Here, the connectingunit 40 is positioned radially outside theteeth 22 b of thestator core 21. - Next, the
coil terminals coil connecting terminals unit 40 to the first axial end of thestator 20. Thus, the twelve concentrated windingcoils 24 are connected by the connectingunit 40, and are configured into a three-phase alternating-current winding that is formed by wye-connecting a U-phase winding, a V-phase winding, and a W-phase winding in each of which four concentrated windingcoils 24 are connected in parallel, in a similar manner toEmbodiment 1. - Moreover, although the coil
terminal guiding members 36 and thecover 37 have not been used, it goes without saying that the coilterminal guiding members 36 and thecover 37 may also be used. - In
Embodiment 2, thebusbar 41N is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 a into thebusbar housing groove 34 at the innermost circumference of the electrically insulatingholder 33, and then thebusbar 41W is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 b into the secondbusbar housing groove 34 from the inner circumferential side. Next, thebusbar 41V is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 b into the thirdbusbar housing groove 34 from the inner circumferential side such that the external electricpower supply terminal 42W of thebusbar 41W that is already mounted is inserted into the omittedportion 42 c of thebase portion 41 b. In addition, thebusbar 41U is mounted onto the electrically insulatingholder 33 by inserting thebase portion 41 b thereof into the fourthbusbar housing groove 34 from the inner circumferential side such that the external electricpower supply terminals busbars portion 42 c of thebase portion 41 b. - According to this assembly procedure, the
busbars coil connecting terminals power supply terminals holder 33 without interfering with each other. Thus, complicated bending steps in which thecoil connecting terminals power supply terminals busbars holder 33, and jigs that are used in the bending steps, etc., are no longer necessary, improving assembly of the connectingunit 40, and enabling costs to be reduced. - Because the
coil connecting terminals power supply terminals busbars holder 33, dimensional precision of the bent portions is increased. - The
coil connecting terminals power supply terminals base portions holder 33, and the two flat surfaces that are constituted by the long sides of the rectangular cross sections of thecoil connecting terminals power supply terminals coil connecting terminals power supply terminals - Because the connecting
unit 40 is disposed radially outside the concentrated windingcoils 24, which are arranged annularly in a circumferential direction, the external electricpower supply terminals base portions 41 b can be connected directly to an external electric power supply (not shown) simply by being extended outside thecylindrical frame 4. Thus, axial dimensions of the rotary electric machine can be reduced, and connecting wiring, etc., between the external electric power supply and the external electricpower supply terminals - Moreover, in each of the above embodiments, a ratio between a magnetic pole count and a slot count in the rotary electric machine is 8:12, i.e., a pole-to-slot ratio is 2:3, but the pole-to-slot ratio is not limited to 2:3, and may also be 4:3, for example.
Claims (9)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2011-245274 | 2011-11-09 | ||
JP2011245274A JP5452570B2 (en) | 2011-11-09 | 2011-11-09 | Rotating electric machine and method of manufacturing stator coil connection unit |
Publications (2)
Publication Number | Publication Date |
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US20130113313A1 true US20130113313A1 (en) | 2013-05-09 |
US8878407B2 US8878407B2 (en) | 2014-11-04 |
Family
ID=48145333
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/450,098 Expired - Fee Related US8878407B2 (en) | 2011-11-09 | 2012-04-18 | Rotary electric machine and method for manufacturing a stator coil connecting unit therefor |
Country Status (4)
Country | Link |
---|---|
US (1) | US8878407B2 (en) |
JP (1) | JP5452570B2 (en) |
CN (1) | CN103107625B (en) |
DE (1) | DE102012212096A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
CN103107625A (en) | 2013-05-15 |
JP5452570B2 (en) | 2014-03-26 |
CN103107625B (en) | 2015-06-17 |
JP2013102633A (en) | 2013-05-23 |
US8878407B2 (en) | 2014-11-04 |
DE102012212096A1 (en) | 2013-05-16 |
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